Model predictive control of water management in PEMFC

Water management is critical for Proton Exchange Membrane Fuel Cells (PEMFC). An appropriate humidity condition not only can improve the performances and efficiency of the fuel cell, but can also prevent irreversible degradation of internal composition such as the catalyst or the membrane. In this paper we built the model of water management systems which consist of stack voltage model, water balance equation in anode and cathode, and water transport process in membrane. Based on this model, model predictive control mechanism was proposed by utilizing Recurrent Neural Network (RNN) optimization. The models and model predictive controller have been implemented in the MATLAB and SIMULINK environment. Simulation results showed that this approach can avoid fluctuation of water concentration in cathode and can extend the lifetime of PEM fuel cell stack.     

Modeling and control of air stream and hydrogen flow with recirculation in a PEM fuel cell system—I. Control-oriented modeling

Transient behavior is one of the key requirements for the vehicular application of proton exchange membrane (PEM) fuel cell. The goal of this study is to develop a dynamic model of PEM fuel cell system (FCS) that is capable of characterizing the mixed effects of gas flow, pressure and humidity. In addition to the model of air supply system, the anode recirculation is also presented in this paper by an analytical model of injection pump. A steady-state, isothermal analytical fuel cell model is adopted to analyze the mass transfer in the diffusion layer and water transportation in the membrane. The liquid water accumulation in the cathode flow channel is described by a finite-rate phase-change model and the cathode flooding in the diffusion layer is also discussed. The transient phenomena in FCS are captured by the mechanical inertia of compressor and flow filling in lumped-parameter volumes of manifolds, anode and cathode.     

Characterization of flooding and two-phase flow in polymer electrolyte membrane fuel cell stacks

A partially flooded gas diffusion layer (GDL) model is proposed and solved simultaneously with a stack flow network model to estimate the operating conditions under which water flooding could be initiated in a polymer electrolyte membrane (PEM) fuel cell stack. The models were applied to the cathode side of a stack, which is more sensitive to the inception of GDL flooding and/or flow channel two-phase flow. The model can predict the stack performance in terms of pressure, species concentrations, GDL flooding and quality distributions in the flow fields as well as the geometrical specifications of the PEM fuel cell stack. The simulation results have revealed that under certain operating conditions, the GDL is fully flooded and the quality is lower than one for parts of the stack flow fields. Effects of current density, operating pressure, and level of inlet humidity on flooding are investigated.     

Anode activation polarization on Pt(h k l) electrodes in dilute sulphuric acid electrolyte

Proton exchange membrane (PEM) fuel cells have been under development for many years and appear to be the potential solution for many electricity supply applications. Modelling and computer simulation of PEM fuel cells have been equally active areas of work as a means of developing better understanding of cell and stack operation, facilitating design improvements and supporting system simulation studies. The prediction of activation polarization in our previous PEM modelling work, as in most PEM models, concentrated on the cathode losses. Anode losses are commonly much smaller and tend to be ignored compared to cathode losses. Further development of the anode activation polarization term is being undertaken in order to broaden the application and usefulness of PEM models in general.     

Experimental analysis of a degraded open-cathode PEM fuel cell stack

The well-known challenges to overcome in PEM fuel cell research are their relatively low durability and the high costs for the platinum catalysts. This work focuses on degradation mechanisms that are present in open-cathode PEM fuel cell systems and their links to the decaying fuel cell performance. Therefore a degraded, open-cathode, 20 cell, PEM fuel cell stack was analyzed by means of in-situ and ex-situ techniques. Voltage transients during external perturbations, such as changing temperature, humidity and stoichiometry show that degradation affects individual cells quite differently towards the end of life of the stack. Cells located close to the endplates of the stack show the biggest performance decay. Electrochemical impedance spectroscopy (EIS) data present non-reversible catalyst layer degradation but negligible membrane degradation of several cells. Post-mortem, ex-situ experiments, such as cyclic voltammetry (CV), X-ray photoelectron spectroscopy (XPS) and X-ray diffraction (XRD) show a significant active area loss of the first cells within the stack due to Pt dissolution, oxidation and agglomeration. Scanning electron microscope (SEM) images of the degraded cells in comparison with the normally working cells in the stack show severe carbon corrosion of the cathode catalyst layers.     

Modeling and simulation of a PEM fuel cell stack considering temperature effects

Management of the water and heat ejected as byproducts in an operating PEM fuel cell stack are crucial factors in their optimal design and safe operations. Models currently available for a PEM fuel cell are based on either empirical or 3-D computational fluid dynamics (CFD). Both models do not fully meet the need to represent physical behavior of a stack because of either their simplicity or complexity. We propose a highly dynamic PEM fuel cell stack model, taking into account the most influential property of temperature affecting performance and dynamics. Simulations have been conducted to analyze start-up behaviors and the performance of the stack in conjunction with the cells. Our analyses demonstrate static and dynamic behaviors of a stack. Major results presented are as follows: (1) operating dependent temperature gradient across through-plane direction of the fuel cell stack, (2) endplate effects on the temperature profile during start-up process, (3) temperature profile influences on the output voltage of individual cells and the stack, (4) temperature influence on the water content in membranes of different cells, and (5) cathode inlet relative humidity influence on the temperature profile of the stack.     

Improving dynamic performance of proton-exchange membrane fuel cell system using time delay control

Transient behaviour is a key parameter for the vehicular application of proton-exchange membrane (PEM) fuel cell. The goal of this presentation is to construct better control technology to increase the dynamic performance of a PEM fuel cell. The PEM fuel cell model comprises a compressor, an injection pump, a humidifier, a cooler, inlet and outlet manifolds, and a membrane-electrode assembly. The model includes the dynamic states of current, voltage, relative humidity, stoichiometry of air and hydrogen, cathode and anode pressures, cathode and anode mass flow rates, and power. Anode recirculation is also included with the injection pump, as well as anode purging, for preventing anode flooding. A steady-state, isothermal analytical fuel cell model is constructed to analyze the mass transfer and water transportation in the membrane. In order to prevent the starvation of air and flooding in a PEM fuel cell, time delay control is suggested to regulate the optimum stoichiometry of oxygen and hydrogen, even when there are dynamical fluctuations of the required PEM fuel cell power. To prove the dynamical performance improvement of the present method, feed-forward control and Linear Quadratic Gaussian (LQG) control with a state estimator are compared. Matlab/Simulink simulation is performed to validate the proposed methodology to increase the dynamic performance of a PEM fuel cell system.     

A theoretical study of inlet relative humidity control in PEM fuel cell

In this paper, the individual roles of inlet anode and cathode humidification, and their influences on PEM fuel cell’s electrical performance are discussed systematically by using a pseudo two-dimensional, two-phase PEM fuel cell model. It follows that the maximum power density point of a PEM fuel cell is strongly dependent on the combination of the inlet anode and cathode humidification conditions. Their influences, however, are predicted to be highly asymmetrical, with the anode and cathode humidification mainly affecting ohmic and concentration overpotential, respectively. The physical explanation to this asymmetry is given with the aid of a detailed set of simulation results. Finally, the developed understanding of their influences are employed to formulate two examples on the use of inlet relative humidity control as a simple and effective method for maximizing the volumetric power density and operating range of PEM fuel cell, respectively.     

A two-phase non-isothermal mixed-domain PEM fuel cell model and its application to two-dimensional simulations

In this paper, a two-phase non-isothermal PEM fuel cell model based on the previously developed mixed-domain PEM fuel cell model with a consistent treatment of water transport in MEA has been established using the traditional two-fluid method. This two-phase multi-dimensional PEM fuel cell model could fully incorporate both the anode and cathode sides, properly account for the various water phases, including water vapor, water in the membrane phase, and liquid water, and truly enable numerical investigations of water and thermal management issues with the existence of condensation/evaporation interfaces in a PEM fuel cell. This two-phase model has been applied in this paper in a two-dimensional configuration to determine the appropriate condensation and evaporation rate coefficients and conduct extensive numerical studies concerning the effects of the inlet humidity condition and temperature variation on liquid water distribution with or without a condensation/evaporation interface.     

Experimental study on dual recirculation of polymer electrolyte membrane fuel cell

Durability and start-up ability in sub-zero environment are two technical bottlenecks of vehicular polymer electrolyte membrane (PEM) fuel cell systems. With exhaust gas recirculation on the anode and cathode side, the cell voltage at low current density can be reduced, and the membrane can be humidified without external humidifier. They may be helpful to prolong the working lifetime and to promote the start-up ability. This paper presents an experimental study on a PEM fuel cell system with anodic and cathodic recirculation. The system is built up based on a 10 kW fuel cell stack, which consists of 50 cells and has an active area of 261 cm². A cathodic recirculation pump and a hydrogen recirculation pump are utilized on the cathode and anode side, respectively. Key parameters, e.g., stack current, stack voltage, cell voltage, air flow, relative humidity on the cathode side, oxygen concentration at the inlet and outlet of the cathode side, are measured. Results show that: 1) with a cathodic recirculation the system gets good self-humidification effect, which is similar to that with an external humidifier; 2) with a cathodic recirculation and a reduction of fresh air flux, the cell voltage can be obviously reduced; 3) with an anodic recirculation the cell voltage can also be reduced due to a reduction in the hydrogen partial pressure, the relative humidity on the cathode side is a little smaller than the case with only cathode recirculation. It indicates that, for our stack the cathodic recirculation is effective to clamp cell voltage at low current density, and a self-humidification system is possible with cathodic recirculation. Further study will focus on the dynamic model and control of the dual recirculation fuel cell system.     

Development of a PEM stack and performance analysis including the effects of water content in the membrane and cooling method

For the use of proton exchange membrane (PEM) fuel cell systems to become widespread, the components required to build one should be minimized. Because a PEM fuel cell has a limited operating temperature range, it requires some kind of cooling method. In this study, different cooling methods were investigated experimentally. A PEM fuel cell stack with an active area of 100 cm² and 8 cells in series was developed and used in this research. When 50% relative humidity inlet gases were supplied (at 15 A of current discharge and 70 °C), cell temperatures at the center increased from around 60 °C to 85 °C, and cell voltage dropped from 4.8 V to 3.2 V because of membrane drying (insufficient cooling). When fully hydrated inlet gases (100% relative humidity) were supplied to the PEM stack at the same test conditions, the cell temperature remained around 65 °C, and stack voltage remained around 5.7 V at 15 A of current discharge. Fully hydrated inlet gases play a positive role both for water transport (when the proton moves from the anode to the cathode) and to maintain the fuel cell stack temperature to prevent stack drying.     

Innovative cathode flow-field design for passive air-cooled polymer electrolyte membrane (PEM) fuel cell stacks

A novel cathode flow-field design suitable for a passive air-cooled polymer electrolyte membrane (PEM) fuel cell stack is proposed to enhance the water-retaining capability under excess dry air supply conditions. The innovative cathode flow-field is designed to supply more air to the cooling channels and further enables deceleration of the reactant air in the gas channels and acceleration of the coolant air in the cooling channels simultaneously along the air flow path. Therefore, the design facilitates the waste heat removal through the cooling channels while the water removal by the reactant air is minimized. The conceptual cathode flow-field design is validated using a three-dimensional PEM fuel cell model. The detailed simulation results clearly demonstrate that the new cathode flow-field design exhibits superior water-retaining capability compared with a conventional cathode flow-field design (parallel flow channel configuration) under typical air-cooled fuel cell operating conditions. This study provides a new strategy to design cathode flow-fields to alleviate notorious membrane dehydration and unstable performance issues in a passive air-cooled PEM fuel cell stack.     

Effects of stack orientation and vibration on the performance of PEM fuel cell

An experimental study is carried out to investigate effects of stack orientation and vibration on the performance of Proton Exchange Membrane (PEM) fuel cell. A 25‐cm² single cell with serpentine anode and straight cathode flow channels is used. The hydrogen flow rate, cathode air temperature, and relative humidity are kept constant at 60 smL/min, 20 °C and 80%, respectively, whereas the cathode air flow rate values are 220, 440, and 660 smL/min as well as free breathing case. An orientation and vibration mechanisms are designed to facilitate different values orientation positions and vibration amplitude and frequency of the stack. The results show that stack orientation and vibration have significant effects on the performance of PEM fuel cell. Based on the results obtained from this study, it can be concluded that optimum positions of cell orientation are 30° and 90° at low and high values of cathode air flow rate, respectively. Also, an improvement in the performance of the fuel cell is achieved when the stack is vibrated with low values of amplitude and frequency. Each of cell maximum power density and maximum hydrogen utilization decreases with increasing each of amplitude and frequency of stack vibration. Copyright © 2014 John Wiley & Sons, Ltd.     

Modeling and control of air stream and hydrogen flow with recirculation in a PEM fuel cell system—II. Linear and adaptive nonlinear control

In this part of the paper, linear and nonlinear multivariable controllers are designed for the air stream and hydrogen flow with recirculation in a proton exchange membrane (PEM) fuel cell system. The focus of the model is to obtain the desired transient performance of air stoichiometric ratio, cathode inlet pressure, and pressure difference between the anode and the cathode. Based on linearization of the nonlinear dynamic model in the first part of this paper, the coupling between control inputs and performance is analyzed first. The phase relationship between the stack voltage and water transport in frequency domain is meaningful to the future humidity estimation and active purge operation. Then, linear quadratic Gaussian (LQG) algorithm based on observer feedback is used for set-point tracking, and a model-predictive controller (MPC) with an on-line neural network identifier is also designed to improve robustness. Compared with decentralized PI controllers, the multivariable controllers improve the transient response and shows better disturbance rejection capability.     

Maintaining desired level of relative humidity throughout a fuel cell with spatially variable heat removal rates

A concept of using the product water to internally humidify the air stream in a PEM fuel cell without external humidification is investigated by a simple, pseudo 2-D model along a single channel. This model takes into account the mass and energy balance, water and heat generation rates, heat removal, and water transport through the membrane. The model and thus the concept were confirmed experimentally using a 5-segment fuel cell. The temperature of each segment could be individually controlled, and the temperature and humidity of air could be measured between each segment. A temperature profile has been established, by applying spatially variable heat removal rates along the cathode channel, that results in relative humidity being close to 100% throughout the cell without any external humidification. The concept may be applied to a fuel cell stack resulting in simplification of the suporting system by avoiding external humidification.     

Analysis of the water and thermal management in proton exchange membrane fuel cell systems

Water and thermal management is essential to the performance of proton exchange membrane (PEM) fuel cell system. The key components in water and thermal management system, namely the fuel cell stack, radiator, condenser and membrane humidifier are all modeled analytically in this paper. Combined with a steady-state, one-dimensional, isothermal fuel cell model, a simple channel-groove pressure drop model is included in the stack analysis. Two compact heat exchangers, radiator and condenser are sized and rated to maintain the heat and material balance. The influence of non-condensable gas is also considered in the calculation of the condenser. Based on the proposed methodology, the effects of two important operating parameters, namely the air stoichiometric ratio and the cathode outlet pressure, and three kinds of anode humidification, namely recycling humidification, membrane humidification and recycling combining membrane humidification are analyzed. The methodology in this article is helpful to the design of water and thermal management system in fuel cell systems.     

Diagnosis of PEM fuel cell stack dynamic behaviors

In this study, the steady-state performance and dynamic behavior of a commercial 10-cell Proton Exchange Membrane (PEM) fuel cell stack was experimentally investigated using a self-developed PEM fuel cell test stand. The start-up characteristics of the stack to different current loads and dynamic responses after current step-up to an elevated load were investigated. The stack voltage was observed to experience oscillation at air excess coefficient of 2 due to the flooding/recovery cycle of part of the cells. In order to correlate the stack voltage with the pressure drop across the cathode/anode, fast Fourier transform was performed. Dominant frequency of pressure drop signal was obtained to indicate the water behavior in cathode/anode, thereby predicting the stack voltage change. Such relationship between frequency of pressure drop and stack voltage was found and summarized. This provides an innovative approach to utilize frequency of pressure drop signal as a diagnostic tool for PEM fuel cell stack dynamic behaviors.     

Thermal modeling and temperature control of a PEM fuel cell system for forklift applications

Temperature changes in PEM fuel cell stacks are considerably higher during load variations and have a negative impact as they generate thermal stresses and stack degradation. Cell hydration is also of vital importance in fuel cells and it is strongly dependent on operating temperature. A combination of high temperature and reduced humidity increases the degradation rate. Stack thermal management and control are, thus, crucial issues in PEM fuel cell systems especially in automotive applications such as forklifts.     

Relationship between pressure drop and cell resistance as a diagnostic tool for PEM fuel cells

An increase in pressure drop, particularly on the cathode side of PEM fuel cell, is a reliable indicator of PEM fuel cell flooding, while an increase in cell resistance is a reliable indicator of fuel cell drying. By monitoring both pressure drop and cell resistance in an operational fuel cell stack it was possible to diagnose either flooding or drying conditions inside the stack. These parameters may be used for making decisions on corrective actions.     

Dynamic behaviors of PEM fuel cells under load changes

In this study, a one-dimensional isothermal single-phase transient model considering the finite-rate water absorption/desorption of membrane was established to study the dynamic behaviors of polymer electrolyte membrane (PEM) fuel cells under different cathode inlet humidity conditions in the presence of voltage step changes. Both the overshoot and undershoot phenomena were observed. Moreover, the distributions of water inside the electrolyte and the influence of that on the response current density of fuel cells were analyzed. When voltage stepped up/down, the water content in anode generally increased/decreased, and the water content in cathode is reversed. If the cathode intake is fully humidified, the water vapor in cathode is always over-saturated causing the change of ionic resistance is determined by that of the water content in anode. If the cathode intake is partially humidified, the change of ionic resistance could maintain within a small range owing to the change of water content in anode can be balanced by that of the water content in cathode.